STRATEGIC OUTCOMES PRACTICE

TECHNICAL ADVISORY BULLETIN

January 2010

www.willis.com

MOTOR FUEL
DISPENSING
SAFETY
Fire! Not an alarm anyone wants to hear,
especially not when the fire is burning at a
major fuel source. But thats what happened
at 10:48 AM, when the general alarm
sounded for a reported fire at the
Department of Public Works Building where
the borough gas pumps were on fire. The fire
chief, first on scene, confirmed a working fire
involving the pumps that dispense both
gasoline and diesel fuel. The first engine
stretched a foam line, while the second
engine stretched another line to back up the
initial fire attack crew.
The re was quickly knocked down and units remained on scene until
the county Hazardous Materials Response Team arrived to assess fuel
and foam run o. A worker had inadvertently backed a garbage truck
into one of the pumps, causing the re.
This is one of just 600 incidents involving service stations or gas
stations1 that re departments across the U.S. responded to, on
average, every day between 2003-2006. This paper will examine the
hazards associated with motor fuel dispensing operations and provide
property loss control guidelines to help reduce the frequency and
severity of such events.

OVERVIEW
Generally speaking, the National Fire Protection Association
(NFPA) classies service stations as an occupancy where gasoline,
diesel fuel or other ammable liquid is transferred to fuel tanks of
self-propelled vehicles. This type of operation can be performed at
traditional fuel dispensing facilities or as part of other occupancies,
such as marine motor fuel dispensing facilities, eet vehicle facilities,
farms, construction sites, repair garages, public transit garages,
municipal garages, car dealerships and in conjunction with
convenience stores, supermarkets or discount stores. They may

range in size from one or two pumps to as

many as a dozen or more and be located inside
and outside of a structure.

CLASSIFICATION
OF LIQUIDS
Chapter 4 of NFPA 30, Flammable and
Combustible Liquids Code, establishes a
uniform system of dening and classifying
ammable and combustible liquids for the
purpose of proper application of this code.
The table below identies this classication:
Gasoline is the most widely used ammable
liquid, generates ammable vapors at ambient
temperatures and has a closed-cup ashpoint
of -45 F. Furthermore, gasoline and almost
all other ammable liquids produce heavierthan-air vapors which tend to settle on the

oor in pits or in depressions. Such vapors may ow along the oor or ground for long distances, be ignited at some
remote area and ash back to the original source.2
Fuel oil is classied 1 through 6, according to its boiling point, composition and purpose. No. 2 is the diesel fuel that
trucks and some cars run on, hence the name "road diesel," and is the same product as heating oil. Although No. 2 diesel
fuel has a ash point higher than 125 F, this material is ammable and, like gasoline, can be ignited by heat, sparks,
ames or other ignition.

CLASS

FLASH POINT*

BOILING POINT**

IA

below 73 F (22.8 C)

below 100 F (37.8C)

IB

below 73 F (22.8 C)

at or above 100 F (37.8C)

IC

at or above 73 F (22.8 C)

below 100 F (37.8C)

II

at or above 100 F (37.8C)

below 140 F (60C)

III

at or above 140 F (60 C)

IIIA

at or above 140 F (60 C) but below

200 F (93 C)

IIIB

at or above 200 F (93 C)

*In Section 4.2.4, of NFPA 30, Flammable and Combustible Liquids Code, Flash Point is dened as the minimum
temperature of a liquid at which sucient vapor is given o to form an ignitable mixture with the air, near the surface of the
liquid or within the vessel used, as determined by the appropriate test procedure.
**In Section 4.2.1, of NFPA 30, Flammable and Combustible Liquids Code, Boiling Point is dened as the temperature at
which the vapor pressure of a liquid equals the surrounding atmospheric pressure.

COMPONENTS OF A MOTOR FUEL

DISPENSING SYSTEM3
Fuel dispensing systems comprise a complex series of equipment that works together to deliver fuel. For example, some
components are designed specically to maintain hydraulic continuity and regulate the direction of ow and uid
pressure. Hydraulic continuity is critical to ensure that fuel and not air or fuel vapor is delivered. In order to supply fuel
from the underground storage tank to the dispenser the pipelines must be essentially free of air and vapor.
In a fuel dispensing system, a check valve allows liquid fuel to ow toward the delivery nozzle and never back toward the
storage tank. In addition, other automatic valves function to regulate the direction of ow or uid pressure as fuel makes
its way to the discharge hose.
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Also in place is a motor-driven pump that furnishes the required pressure to move fuel
from the storage tank to the dispenser, through a metering device and ultimately to the
discharge hose and nozzle. Metering devices in both gasoline and diesel systems are
positive displacement meters in which nite quantities of fuel are separated into
compartments of known volume. Each time the meters crankshaft makes a full
revolution, an exact quantity of fuel has been metered. This shaft revolution provides
the most accurate indication of the amount of fuel delivered. The amount delivered is
then registered via a mechanical or electronic computer that indicates the price of the
delivery, the amount delivered and the unit cost.
One of a fuel dispensing systems primary control devices is the discharge nozzle, which
performs three basic functions: 1) controls fuel delivery, 2) prevents vehicle tank overll (when the nozzle is so equipped) and 3) prevents the discharge hose from draining
after completion of a delivery.
Since a fuel dispensing system consists of many integral components, the failure or
malfunction of one element can aect another one and impair the correct operation of
the entire system. As a result, all equipment, mechanisms and devices need continuous
maintenance, inspection and testing in compliance with manufacturers or other
agencys specication to ensure proper operation.

LOSS CONTROL GUIDELINES

NFPA 30A, Motor Fuel Dispensing Facilities and Repair Garages provides a list of
safeguards for dispensing liquid and gaseous motor fuels into the fuel tanks of
automotive vehicles and marine craft. Some guidelines contained in this document
include:
1.

Locate dispensing devices installed outside motor fuel dispensing stations as

follows:
 Ten feet or more from property lines
 Ten feet or more from buildings, other than canopies, having combustible
exterior wall surfaces or buildings having noncombustible exterior wall
surfaces that are not part of a one-hour-re-resistive assembly
 The nozzle, when the hose is fully extended, will not reach within 5 ft. (1.5 m) of
building openings

Since a fuel
dispensing system
consists of many
integral
components, the
failure or
malfunction of one
element can affect
another one and
impair the correct
operation of the
entire system. As
a result, all
equipment,
mechanisms and
devices need
continuous
maintenance,
inspection and
testing in
compliance with
manufacturers or
other agencys
specification to
ensure proper
operation.

2. Make provisions to prevent spilled liquids from flowing into the interior of
buildings. This may include grading driveways, raising door sills or other means.
3. Consider an automatic fire suppression system. A traditional wet pipe sprinkler
system may not be suitable in areas where the air temperature is less than 40 F.
Dry type sprinkler systems, pre-action sprinkler systems, foam or dry chemical
systems may be needed.
4. Provide each motor fuel dispensing facility or repair garage with fire extinguishers.
The maximum travel distance to an extinguisher is 100 ft.
(30.48 m).
5. Do not use smoking materials, matches and lighters within 20 ft. (6 m) of areas used
for fueling, servicing fuel systems or receiving or dispensing Class I and Class II
liquids.
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6. Install electrical wiring and electrical utilization equipment in

accordance with NFPA 70, National Electric Code (NEC). Use
only electrical equipment that is specified in the NEC.
7.

Provide fuel dispensing systems with one or more clearly

identified emergency shutoff devices or electrical disconnects.
They should be located in approved locations but not less than
20 ft. (6 m) or more than 100 ft. (30 m) from the fuel dispensing
devices that they serve.

8. Strictly enforce good housekeeping practices. This includes

maintaining clear aisle space to fire fighting equipment, using
approved covered metal receptacles where appropriate, and
keeping floors clean and free of oil and grease.
9. Use only listed hose assemblies to dispense fuel. Hose length at
automotive fuel dispensing facilities should not exceed 18 ft. (5.5
m). Where hose length at marine motor fuel dispensing facilities
exceeds 18 ft. (5.5 m), secure the hose to protect it from damage.
Underwriters Laboratories UL 330, Standard for Safety for Hose
Assemblies for Dispensing Flammable Liquids, covers hose and
hose assemblies, including vapor recovery hose and assemblies
for use on dispensing devices for flammable liquids. Hoses
should be checked daily for cuts, cracks, bulges, blisters, flat
spots, kinks or worn spots.
10. Storage tanks may be installed aboveground, belowground or
inside buildings. Proper safeguarding is needed for openings and
connections to tanks for venting, gauging, filling and
withdrawing. Factors to consider when choosing the size and
number of storage tanks include the characteristics of the liquid
stored, the design of the tanks and their foundation and
supports, the size and location of vents and the piping and its
connections.

The Petroleum Equipment Institute, a

trade association whose members
manufacture, distribute and service
petroleum marketing and liquid-handling
equipment, publishes a 36-page document
titled Recommended Practices for Inspection
and Maintenance of Motor Fuel Dispensing
Equipment. This publication provides a basic
reference that consolidates published and
unpublished information from equipment
manufacturers, installers and end users
concerning the proper inspection and
maintenance of motor vehicle fueldispensing equipment. The recommended
practice applies to fueling equipment
intended to dispense gasoline, diesel and
related petroleum products into motor
vehicles at commercial and retail fueling
facilities. Equipment covered includes all
above-grade, liquid- and vapor-handling
components from the base of the dispenser
cabinet to the nozzle spout.

SUMMARY
While not every incident can be avoided,
proactive loss-control measures are essential,
especially given the inherent hazards of
ammable liquids. With proper design and
safeguards in place, you can greatly minimize
the potential for a re or emergency wherever
motor fueling dispensing operations
take place.

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CONTACTS
For additional information, please contact
David H. Gluckman, ARM, CBCP, CFPS
Senior Risk Control Consultant
Willis Strategic Outcomes Practice
973 829 2920
david.gluckman@willis.com
Joe Stavish, PE
National Technical Director, Property Risk Control
Willis Strategic Outcomes Practice
973 829 2955
joe.stavish@willis.com

The objective of our publication is to provide a general overview and discussion of issues relevant to loss
control. The comments and suggestions presented should not be taken as a substitute for advice about any
specific situation.

Information regarding service stations/gas stations; the documentation was taken from the NFPA
Report Structure Fires in Stores and Other Mercantile Properties. If you wish to obtain the entire
report, please log onto the NFPA website at www.nfpa.org; the entire report is available for NFPA
members only.
2
Arthur E. Cote, P.E., et al., Fire Protection Handbook, Eighteenth Edition (Quincy: National Fire
Protection Association, 1997), pp. 4-59 though 4-66.
3
National Institute of Standards and Technology, Retail Motor-Fuel Dispensers and Consoles,
Gaithersburg, MD, 2003, pp. 3-1-3-28.

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